Aldi and Ocado Celebrate Breakthrough in Sustainable Grocery Trials

Image Credit: GoUnpackaged

Aldi and Ocado have successfully tested in-store refill stations, achieving refill rates of up to 57%. Even more impressively, 86% of containers were returned without the need for deposit incentives. The trials, run by GoUnpackaged’s Refill Coalition, indicate that refillable can outperform single-use packaging in terms of environmental impact in just two cycles.

For 16 months, Aldi rolled out refill stations at their Solihull and Leamington Spa stores, introducing modular refill ‘vessels’ into the supply chain. These refillable containers were expected to replace up to 24 single-use plastic packages per vessel.

Meanwhile, Ocado launched a similar initiative online, selling returnable containers through its e-commerce platform for eight months. These pre-filled containers were delivered alongside regular grocery orders. They could be returned for reuse, replacing up to five single-use plastic packs in each transaction.

The results have been promising: In-store refills peaked at 57%, with an average sales share of 30%, while Ocado’s online reusable products hit a high of 43% weekly sales share, averaging 16%. Customer satisfaction was also exceptional, with 97% of consumers finding the refill system hygienic and 89% finding it easy to use.

Aldi’s refill system is integrated seamlessly into its existing logistics. An impressive 86% of vessels were returned, all without deposit incentives, and staff reported that restocking the refill stations was quick and straightforward.

Ocado’s online trial also showed promising results, with 100% of customers reporting clean packaging and product ratings consistently high at 4.8 and 4.9 stars. Moreover, 96% of customers said they would purchase the packaging again.

An independent Life Cycle Analysis (LCA) further corroborated these findings, revealing that reusable vessels outperform single-use alternatives in just two reuse cycles. They offer reduced packaging waste and a smaller carbon footprint without disrupting operations.

The Refill Coalition believes these trials have proven that reusable systems are not only scalable but also commercially viable. The initiative has also demonstrated the potential for competitors to collaborate, share costs and risks, and drive further innovation.

“We are extremely proud of our collective work to design and launch these new reuse and refill systems,” said Catherine Conway, founder of GoUnpackaged. “They offer a clear path toward tackling the single-use plastics crisis, delivering tangible benefits across environmental, operational, and consumer metrics.”

“This trial marks a significant milestone for sustainable retail,” continued Giles Hurley, CEO of Aldi UK & Ireland. “The results show that customers are not only ready for reuse—they’re demanding it. We’re excited to explore how we can take this further.”

Marks & Spencer, Morrisons, Waitrose & Partners, Sainsbury’s, and Lidl also played a significant role in the project’s early stages.

Aldi’s refill initiative was recognized as a finalist at the Sustainability Awards last year for its groundbreaking approach to in-store reuse.

The pilot was funded by Innovate UK’s Smart Sustainable Plastic Packaging Challenge. When Aldi ended its trial on March 11th, the company clarified that the limited run was always part of the plan, though according to The Grocer, it couldn’t be scaled up due to “lack of wider retailer adoption. "

Other reuse initiatives are underway globally, with Unilever conducting pilots in supermarkets and local markets in Bangladesh, Sri Lanka, and Indonesia. Their collaborations with companies like Vega Innovations, Bopinc, and Alner aim to reduce the use of flexible plastic sachets while giving consumers greater control over product quantity and pricing.